Contents · Contents CHAPTER 1 ... CHAPTER 6 COMPRESSOR LIFTING AND INSTALLATION ... copyright of...

Vol. 2.5 © 2015 Hanbell Precise Machinery Co., Ltd. All rights reserved

Contents

CHAPTER 1. INTRODUCTION ................................................................... 1

FEATURES ................................................................................................................ 1

AMBIENCE ............................................................................................................... 1

CHAPTER 2. BASIC DESIGN ...................................................................... 2

2.1 COMPRESSOR NOMENCLATURE ................................................................................ 2

2.2 APPLICATION LIMITS ............................................................................................. 2

2.3 COMPRESSOR SPECIFICATIONS ................................................................................. 4

2.4 COMPRESSOR OUTLINE .......................................................................................... 8

2.5 CONNECTIONS ................................................................................................... 13

2.5.1 Suction/discharge/economizer flange size .................................................................. 13 2.5.2 Size of bushings for motor liquid injection .................................................................. 16

2.6 COMPRESSOR STRUCTURE .................................................................................... 17

CHAPTER 3. CAPACITY CONTROL SYSTEM ............................................. 18

3.1 INLET GUIDE VANES ............................................................................................. 18

3.1.1 Control of inlet guide vanes ........................................................................................ 20

3.2 VANE ACTUATOR CONTROL ................................................................................... 21

3.2.1 Actuator data ............................................................................................................. 21 3.2.2 Electrical connections ................................................................................................. 21 3.2.3 Digital BCD switch setting ........................................................................................... 23 3.2.4 Sensitivity .................................................................................................................. 24 3.2.5 Duty Cycle .................................................................................................................. 24 3.2.6 ON/OFF Setting .......................................................................................................... 25 3.2.7 Light Indication .......................................................................................................... 26 3.2.8 Problems and Troubleshooting ................................................................................... 27 3.2.9 Proportional Control .................................................................................................. 28 3.2.10 Acuator Capacity Control .......................................................................................... 28

3.3 SURGE AND STALL .............................................................................................. 29

3.3.1 Equation of safety margin line .................................................................................... 30

3.4 HOT GAS BYPASS ................................................................................................ 31

3.5 PROPORTIONAL VALVE ........................................................................................ 32

CHAPTER 4. LUBRICATION SYSTEM ....................................................... 33

4.1 OIL CIRCUIT ...................................................................................................... 33

4.2 OIL PUMP ........................................................................................................ 34

4.2.1 Specifications of the oil pump .................................................................................... 34 4.2.2 Features of oil pump .................................................................................................. 34 4.2.3 Protection in oil line ................................................................................................... 35


4.3 OIL COOLER ...................................................................................................... 36

4.4 EXTERNAL OIL FILTER ........................................................................................... 36

4.5 OIL & REFRIGERANT CIRCUITS ................................................................................ 37

4.5.1 Oil temperature control in the oil tank ....................................................................... 38

4.6 LUBRICANTS ..................................................................................................... 41

4.6.1 Lubricant table ........................................................................................................... 41 4.6.2 Precautions in changing of oil ..................................................................................... 41 4.6.3 Oil change .................................................................................................................. 43

CHAPTER 5. MOTOR ............................................................................. 44

5.1 MOTOR COOLING ............................................................................................... 44

5.2 MOTOR PROTECTOR ........................................................................................... 47

5.3 ELECTRICAL DATA AND DESIGN ............................................................................... 50

5.3.1 Motor design：Y-ΔStarting ....................................................................................... 50

5.3.2 Characteristics of Starting .......................................................................................... 50

5.3.3 Motor design：Direct on line start/soft start/inverter start ........................................ 51

5.3.4 MCC & LRA ................................................................................................................. 52 5.3.5 Grounding .................................................................................................................. 53 5.3.6 Insulation for high voltage main terminals .................................................................. 53

5.3.6.1 Method 1: ........................................................................................................................................... 53 5.3.6.2 Method2: ........................................................................................................................................... 53

5.3.7 Protective measures of electric shock ......................................................................... 54

5.4 COMPRESSOR ELECTRICAL AND SAFETY PRACTICES ...................................................... 56

5.4.1 Electrical Safety Precautions: ...................................................................................... 56 5.4.2 The Inspection and Preparation before Electrical Wiring ............................................. 56

5.4.2.1 Inspection of Unpacking ..................................................................................................................... 56 5.4.2.2 Cable Selection: .................................................................................................................................. 57

5.4.3 Power Wiring Detail: .................................................................................................. 57 5.4.3.1 Caution for wiring .............................................................................................................................. 57 5.4.3.2 Making of cable end and the connector ............................................................................................. 58

5.4.4 Limitation of power supply ......................................................................................... 60

CHAPTER 6 COMPRESSOR LIFTING AND INSTALLATION ......................... 61

6.1 COMPRESSOR LIFTING ......................................................................................... 61

6.2 COMPRESSOR MOUNTING .................................................................................... 61

6.3 COMPRESSOR PROTECTION DEVICE ......................................................................... 63

6.4 COMPRESSOR ACCESSORIES .................................................................................. 64

6.5 OPERATION AND MAINTENANCE ............................................................................ 65

6.5.1 Compressor starting ................................................................................................... 65 6.5.2 Compressor control logic ............................................................................................ 67

6.6 TROUBLESHOOTING ............................................................................................ 68

1


Chapter 1. Introduction

This manual is intended as a guide for application engineers, consultants, sales engineers, and HVAC designers to use Hanbell RT series centrifugal compressors. The copyright of content in this technical manual belongs to Hanbell Precise Machinery Co., Ltd.. Neither this publication nor any part of it may be reproduced or transmitted in any form or by any means without the prior permission of Hanbell Precise Machinery Co., Ltd..

Features

HFC-134a - chlorine-free refrigerant（Zero ODP）.

COP - the highest-efficiency centrifugal compressor for HFC-134a in the market. Maximum pressure – designed for the high pressure up to17 bar. Compressor - semi-hermetic design. Refrigerant cycle with - high-efficiency two-stage compression with economizer.

- high-efficiency motor. Shaft – made of high-strength alloy steel. Impellers – closed type made of high-strength aluminum. Bearings - durable for 50,000-hour operation without overhaul. Semi-hermetic motor – independent cooling by liquid refrigerant. Gear – less mechanical loss (JIS 0). Enclosure - IP54 protection.

Ambience

RT series compressors should be stored and operated within the following ambient temperature.

Storage: -20℃ to 60℃ (-4℉ to 140℉)

Operation(Water-cooled): ET:-8℃~20℃ (17℉ to 68℉);CT：20℃~50℃ (68℉ to 122℉)

Operation(Heat pump): ET:-8℃~20℃ (17℉ to 68℉);CT：20℃~60℃ (68℉ to 140℉)

Note: Please refer to “Application limits” in page 2 for allowable operating conditions and Hanbell selection software for detailed performance data.

2


Chapter 2. Basic design

2.1 Compressor nomenclature

RT – xx x x

2.2 Application limits

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

500 700 900 1100 1300 1500 1700 1900 2100

Pr

Qo[KW]

Compressor Performance Map

Below dead point is

controlled with MCC

Surge line

IGV + HGBP

Stall zone

IGV0%IGV10%

IGV20%

IGV40%

IGV100%

IGV30%

Safety margin line Compressor Operating Zone

Figure 2.1 RT series application limits

1. Pressure ratio: the ratio of discharge pressure (abs.) over suction pressure (abs.).

*pressure sensors should be installed on the compressor discharge and suction pipe. If the sensors are installed on condenser and evaporator, pressure drop need to be considered.

2. Surge line: the curve formed by connecting surge points of each IGV opening. 3. Safety margin line: the curve formed by translating the surge line by a safety

margin to be the upper application limit of pressure ratio for each IGV opening.

RT model－Centrifugal compressor

Model

0 – Air-conditioning ΔT = 30°C

1 – Heat pump ΔT = 40°C

Empty – Standard

T – Dual-IGV

E – High Efficiency

3


4. Stall zone: Rotating stall is a local disruption of airflow within the compressor which continues to provide compressed air but with reduced effectiveness. Stall zone is defined to confine application of the compressor under unsteady flow with small volume flow.

4


2.3 Compressor specifications

Model RT-120 RT-130 RT-140

Refrigerant R134a

Compressor

Type Two-stage with speed-up gearing

Pressure ratio* LP HP LP HP LP HP

1.63 1.55 1.63 1.55 1.63 1.55

Mass flow rate* kg/sec 11.95 13.54 13.01 14.73 13.43 15.21

Volume flow (Suction)* ㎥/hr 2,466 1,740 2,684 1,893 2,711 1,954

Rated speed rpm 11,700 12,000 12,000

Inlet guide vane control IGV1

10~100% continuous


10~100% continuous(optional)

Transmission

Type Helical gear

Lubrication Built-in oil pump

Lubricant charge Liter 38

Motor

Type 3 Phase, 2 Pole, Induction

Starting Y-△ Starting, Direct starting

Voltage (50/60 Hz) V 380~600,10k/6k/4k/3k

Insulation Class F

Protection PTC,Pt100/Pt1000

Oil heater kW 2x0.5

Chamber heater kW 2x0.3

Dimension (LxWxH) m 2.30 x 1.20 x 1.02

Weight kg 3,500

Hydrostatic pressure test kg/cm²g 22

Table 2.1 Refrigeration Compressor specifications

*Under CT/ET=36℃/6℃

*Setting IGV1=0% applied only in startup, in regular operating should set IGV1≧10%

*IGV2 is optional for RT160, RT180, RT200. *IGV2 (Radial IGV) is standard for RT111, RT161, RT221

Note：The applicable power in 50/60 Hz is as below：

Voltage RT-120~140

380V~600V ○

3kV/3.3kV ○

6kV/6.6kV ○

10kV ○

5



Refrigerant R134a

Compressor



1.63 1.55 1.63 1.55 1.63 1.55



Rated speed rpm 9400 8900


10~100% continuous


10~100% continuous(optional)

Transmission

Type Helical gear



Motor



Voltage (50/60 Hz) V 380~600,10k/6k/4k/3k

Insulation Class F


Oil heater kW 2x0.5

Chamber heater kW 2X0.3


Weight kg 4,500


Table 2.2 Refrigeration Compressor specifications



*Dual IGV for high IPLV application.


Voltage RT-160~200

380V~600V ○

3kV/3.3kV ○

6kV/6.6kV ○

10kV ○

6



Refrigerant R134a

Compressor



1.63 1.55 1.63 1.55 1.63 1.55



Rated Speed rpm 8,200

Inlet guide vane control IGV1 10~100% continuous

Inlet guide vane control IGV2 Not applicable

Transmission

Type Helical gear



Motor



Voltage (50/60 Hz) V 380~600,10k/6k/4k/3k

Insulation Class F


Oil heater kW 2x0.5

Chamber heater kW 2X0.3


Weight kg 4,500


Table 2.3Refrigeration Compressor specifications



*This frame does not include dual-IGV structure.


Voltage RT-240~280

380V~600V Optional

3kV/3.3kV ○

6kV/6.6kV ○

10kV ○

7



Refrigerant R134a

Compressor



1.91 1.73 1.91 1.73 1.91 1.73



Rated Speed rpm 12,000 9,400



Transmission

Type Helical gear


Lubricant charge Liter 33 57 57

Motor



Voltage (50/60 Hz) V 380~600,10k/6k/4k/3k

Insulation Class F


Oil heater kW 2x0.5

Chamber heater kW 2x0.3


Weight kg 4,500


Table 2.4 Heating Compressor specifications



*Dual-IGV structure is standard


Voltage RT-111 ~ 161 RT-221

380V~600V ○ Optional

3kV/3.3kV ○ ○

6kV/6.6kV ○ ○

10kV ○ ○

8


2.4 Compressor outline

Compressor outline (RT-120~140) (Low voltage)

9


Compressor outline (RT-120~140) (High voltage)

10


Compressor outline (RT-160~200, 161, 221) (High & low voltage)

11


Compressor outline (RT-240~280) (High & low voltage)

12


Compressor outline (RT-111) (High & low voltage)

13


2.5 Connections

2.5.1 Suction/discharge/economizer flange size

Figure 2.2 Flange size

Position Size A

B D E F G

Piping thick.

(JIS) (GB) (GB)

RT-120~140 RT-101

Suction 8" 218 221.5 305 350 30 12 25 11

Discharge 6" 167 170.5 260 305 28 12 25 10.5

Mid.-press. (Eco.)

2 1/2" 77.5 77.5 140 175 20 8 19 7

RT-160~280 RT-161, RT-221

Suction 12" 320 327.5 430 480 36 16 27 14

Discharge 8" 218 221.5 305 350 30 12 25 11

Mid.-press. (Eco.)

4" 116 116 185 225 24 8 23 8.5

Remarks

※Material-standard JIS 20 kg/cm2g steel unit: mm

※thickness must be equal to the standard or larger

Table 2.5 Flange dimensions

Note：

1. Please weld steel pipes onto flanges by butt-welding and make sure debris has been cleaned, otherwise the compressor might be damaged badly during running. Flow velocity in the discharge side of the compressor could be as high as 15~20 m/sec. High-speed discharge gas will make noise in discharge connection. In order to decrease the noise level, it’s recommended to round sharp edges of joints of piping.

2. The discharge and suction piping is recommended to be one size larger than that of discharge and suction flanges to reduce pressure drop and noise level. If the noise

14


level is high in discharge side, it is suggested to increase the piping thickness or enclose with acoustic foam shown in Figure 2.3 & 2.4.

2-1. To make the compressor maintenance easier, it is recommended to install butterfly valve (Bray 40) on the pipe between compressor discharge port and condenser. Therefore, the remaining gas inside compressor can be led to the condenser without additional refrigerant recovery procedure. As mentioned in Note number 2 above, the pipe is recommended to be one size larger than regular dimension to reduce pressure drop.

Reference table for ressure drop of butterfly valves:

Model

Dimension

(inch)

Flow

Resistance

Coefficient

(K)

Density

(kg/m3)

Flow

Speed

(m/s)

Pressure

Drop

(kPa)

RT-120 8〞 0.5 45 14.69 2.43

RT-130 8〞 0.5 45 15.98 2.87

RT-140 8〞 0.5 45 16.49 3.06

RT-160 10〞 0.51 45 12.70 1.9

RT-180 10〞 0.51 45 14.61 2.4

RT-200 10〞 0.51 45 15.72 2.8

RT-240 10〞 0.51 45 19.05 4.2

RT-260 10〞 0.51 45 20.85 5.0

RT-280 10〞 0.51 45 21.80 5.5

RT-111 8〞 0.5 59 10.94 1.77

RT-161 10〞 0.51 59 12.29 2.27

RT-221 10〞 0.51 59 14.19 3.03

15


Figure 2.3 Discharge and suction piping

Note: Residue from welding might damage the compressor seriously.

Figure 7. 排氣連接管隔音包覆法

Figure 2.4 Enclosure of piping connection

Heatproof rubber Laminated lead

(2~3mm)

Acoustic foam Gummed tape

16


2.5.2 Size of bushings for motor liquid injection

Figure 2.5 Size of bushings

Mode Size A B C D E F

RT-120~140 RT-111

Liquid injection inlet 3/4" Flare

Liquid injection outlet

1 1/8" Copper 52 75 35 28.8 42 12

RT-160~280 RT-161, RT-221

Liquid injection inlet 7/8" Copper 52 60 35 22.6 42 12

Liquid injection outlet

1 5/8" Copper 52 75 35 41.6 52 12

Remarks unit: mm

Table 2.6 Dimensions of bushings

Note：To effectively control motor temperature, some service valve can be installed in the

piping before the bushing for motor liquid injection to provide adequate amount.

17


2.6 Compressor structure

Figure 2.6 Compressor structure

NO. Description NO. Description

1 Suction 8 Oil drain valve

2 Discharge 9 Sight glass (oil level)

3 Sight glass (motor) 10 Oil return flange

4 Sight glass (refrigerant level) 11 Gas return pipe

5 Power bolt 12 Inlet flange for motor cooling

6 Oil return connection 13 Outlet flange for motor cooling

7 Oil pump 14 Actuator

10

3

2

4

6 5 13 7

9

11

8

12 1

14

18


Chapter 3. Capacity control system

3.1 Inlet guide vanes

The cooling capacity of RT Series centrifugal compressors are modulated with change in angles of inlet guide vanes. Before refrigerant reaches the 1st impeller for compression, a pre-rotation angle has developed for changing in adiabatic head for control of its cooling capacity.

Figure 3.1 Inlet guide vanes in the compressor

Figure 3.1 Compressor inlet

As illustrated in Figure 3.1, RT series standard water-cooled compressors have first inlet guide van (IGV1). Refrigerant gas from the evaporator outlet flows through the suction nozzle to the compressor suction inlet. After the inlet nozzle, gas flow velocity increases due to the narrow passage. By changing angles of IGV1, refrigerant gas enters with a pre-rotation angle into impellers. Both gas flow speed and pressure will increase with rotation of impellers.

IGV before each impeller stage could only controls energy head of that impeller stage. In

order to get wider energy head and control range, it requires an additional IGV2 before the second impeller stage. Radial IGV2 before second impeller can interact with IGV1 to bring more flexibility for part load capacity control and better IPLV value. 2 IVG design is standard for heat pump model and optional for RT-160T~ 200T.

Actuator

Suction

Inlet guide vane

Impeller

19


Figure 3.2 System with an economizer

Figure 3.2 illustrates a refrigerant circuit with an economizer. RT series centrifugal compressors are a two-stage compression design. Therefore, an economizer should be installed for better system efficiency. In general, system efficiency will increase by economizer operation, but there are various economizer designs to cope with suction/ discharge pressures in different system applications.

Figure 3.2.1

Figure 3.2.1 Refrigerant cycle diagram with economizer contributes higher efficiency and it is obvious that 7% of capacity gain occurs between point 5 & point 6.

20


3.1.1 Control of inlet guide vanes

Angles of inlet guide vanes are automatically controlled through a vane actuator with a lever arm. Automatic adjustment of angles of guide vanes is made with loading, from full load with vanes widely opened to minimum load with guide vanes completely closed.

Opening of the vane actuator in percentage (%) bears a linear relation to the control signal voltage, but not to angles of inlet guide vanes. The cooling capacity of centrifugal compressors varies according to angles of guide vanes which change pre-rotation angles

into impellers. In this case, vane actuator’s opening in percentage (％) is not the same as

the cooling capacity in percentage (％).

Note 1: When inlet guide vanes are completely closed, a small hole will be formed in the

middle as illustrated in Figure 3.3 to keep a basic amount of gas flow into the compressor when operating.

When inlet guide vanes are fully closed, only Min. mass flow passes so the smallest

cooling capacity will be established. Note 2: The lower pressure ratio stands for the lower minimum unloading capacity.

Therefore, it is NOT applied to all operation conditions that opening of the vane

actuator could be set less than 10％. Please refer to HANBELL selection software

for details of opening of guide vanes in percentage before operation.

Note 3: IGV=0% for start up only. During operation IGV1 should ≧10%

Note 4: T means models with dual-IGV, there is specific correlation between IGV1 and

IGV2. Please contact HANBELL sales representatives for the detail.

Figure 3.3 Close Inlet guide vanes completely

Min. mass flow

21


3.2 Vane actuator control

3.2.1 Actuator data

Power supply 220V AC 1PH ,50/ 60Hz

Casing IP67/NEMA 4X : water and dust proof

Motor

DC motor, duty cycle 75%

Insulation Class F

Built-in thermistor protection(90±5℃ trip) to prevent

motor burn

Ambience Ambient temperature : -30℃~+65℃

Relative humidity : 30~95％

Proportional valve driver board

Input signal : 4~20mA, 1~5V, 2~10V

Output signal : 4~20mA, 2~10V

Cable cap 1/2” PS

Table 3.1 Actuator data

Note：

1. Compressors shipped before the end of 2012 were equipped with yellow actuators. Consult Hanbell representatives for detailed technical support. Current standard is equipped with blue actuators,

2. Operating in environment under 25℃ requires additional space heater (optional)

to keep dry inside the driver, and prevent shrinkage of spare parts caused by low temperature, high humidity.

3. Consult Hanbell representatives if explosion proof actuator is needed. 4. Add 3-ampere fuse in power supply to protect the actuator.

3.2.2 Electrical connections

All actuator control elements are wired to a terminal strip under a main cover. Remove

the cover and insert cables through cable connectors in order to reach the terminal strip. The connection should be made according to Figure 3.4. Before the connection, please make sure the power voltage is correct. After the connection of terminals, operate the actuator manually to a half-open position and make preliminary check of its wiring.

22


Figure 3.4 Wiring diagram

Note 1: Input and output signals could be voltage or current. The factory default is 4~20mA. Note 2. Control signal wire should install with shielded wire to prevent interference, if the compressor is VFD or High-Voltage series.

23


Figure 3.5 Control board of the actuator

3.2.3 Digital BCD switch setting

8 7 6 5 4 3 2 1

ON OFF OFF OFF ON OFF OFF ON Factory default

OFF ON 4~20mA input

OFF OFF 1~5V input

ON OFF 2~10V input

OFF ON OFF 4~20mA output

ON OFF ON 2~10V output

OFF Under 20mA/5V/10V, IGV opening is at fully-open position.

ON Under 20mA/5V/10V, IGV opening is at fully-close position.

ON OFF When input signal fails, IGV opening will be at fully-close position.

OFF ON When input signal fails, IGV opening will be at fully-open position.

ON ON When input signal fails, IGV opening will stop at the final position. WARNING : #6 should be kept as OFF and must not be adjusted.

Table 3.2 Digital BCD switch setting Note :

1. When the actuator is powered, the position of digital BCD switch shouldn’t be changed.

2. If the input signal fails, IGV1 should be adjusted to “fully-close” position. 3. If the input signal fails, IGV2 should be adjusted to “fully-open” position.

Function Setting

S1,2 Input signal selection “4~20mA”, set 1-ON/2-OFF “1~5V”, set 1-OFF/2-OFF “2~10V”, set 1-OFF/2-ON

S3,4,5 Output signal selection “4~20mA”, set 3-OFF/4-ON/5-OFF “2~10V”, set 3-ON/4-OFF/5-ON

When S6 is set as “OFF,”

24


Function Setting

S6 Input signal selection : 4mA→IGV fully-close 20mA→IGV fully-open

Set 6-OFF

S3,4,5 Position selection (When feedback signal fails)

“IGV at fully-close position”, set 7-OFF/8-ON “IGV at fully-open position”, set 7-ON/8-OFF “IGV stops moving”, set 7-ON/8-ON

or set 7-OFF/8-OFF

Note : Factory default settings are input signal 4~20mA, output signal 4~20mA; IGV opening at fully-open position: 20mA, sensitivity 1 and when input signal fails, IGV opening will be at fully-close position.

3.2.4 Sensitivity

Sensitivity setting: the lower setting value, the higher sensitivity If the actuator is too sensitive, it will result in hunting (overshoot or undershoot and the target is never reached.) However, if the tolerance of setting point in chiller controller is too small, the same problem may occur. When hunting happens, please check if these two setting values are appropriate.

Note: 1. When set as “0”, it is the lowest sensitivity; 0~90° can be divided into 10 moves. 2. When set as “1”, it is the highest sensitivity; 0~90° can be divided into 50 moves. 3. When sensitivity switch is adjusted by one step, 5 moves will be reduced e.g. from SW1 to SW2, from SW2 to SW3 and from SW3 to SW4.

Only authorized personnel are allowed to change the settings.

3.2.5 Duty Cycle

The useful cycle setting and standard running time/rest time of actuator, according to IEC34-1 (International Electro technical Commission) is defined as:

Starting Frequency=Running Time/(Running Time +Rest Time)*100%

Rest Time = Running Time *(1- Starting Frequency)/Starting Frequency

25


Ex. In a compressor at 50Hz, the actuator’s Duty Cycle(Starting Frequency)

75%，Running Time 18sec,

Rest Time =18*(1-75%)/75%=6sec. When the controller commands to do:

1. Full-load control (IGV=0%→100% or 100%→0%), Cycle Time is at least 18+6=24sec.

2. Part-load modulation, Cycle Time is：｜Capacity Difference%｜*(18+6)

Ex. IGV=30%→80%, Cycle Time =｜30%-80%｜*(18+6)=12sec

Note：If each movement of openness≦10% and the chilled water response cycle

is 15 seconds, the operation interval can be set as 15 seconds. 10%*(18+6) ≦15

Note: It is more complicated to split command time into many parts in control logic. It is recommended to set Full-load 24sec as command cycle time for easier control. To prevent overheat due to frequent restart, number of starts should be less than 3 times per minute.

3.2.6 ON/OFF Setting

ON/OFF setting is as default. When special signals are required, under some circumstances, reset is necessary. 1. ON setting a. After long pressing “SET” button for 2 sec, LD9 shines and manual mode is available. b. Continuously press “UP” button until the actuator is fully open, LD2 shines and input

signal 5V or 10V or 20mA. c. Press “MODE” button to complete ON setting. 2. OFF setting a. Continuously press “DOWN” button until the actuator is fully close, LD1 shines and input

signal 1V or 2V or 4mA. b. Press “MODE” button to complete OFF setting. 3. After finishing either aforementioned setting, press “SET” button.

26


3.2.7 Light Indication

LD1 Fully-close LD4 Input voltage error LD7 Output signal short LD2 Fully-open LD5 Output signal error LD8 Motor over current LD3 Power LD6 Motor temp trip LD9 Manual mode

Light Possible Cause Solution

LD3 does not

shine

a. Power is not on a.Check if power is supplied (proportional valve driver board terminals #4&#5)

b. Voltage is higher than 260V so proportional valve driver board burns

b.Check if input voltage is correct.

c. Wrong #8&#9 wiring connection in variable resistance

c.Check if wiring is correct.

d. Proportional valve driver board fails

d.Return it to the manufacturer for checking

LD5 shines

a. Input signal set as 2-10V, but input 4-20mA signal

Check if SW1 setting coincides with input signals.

b. Input signal set as 2-10V, but input signal is larger than 13.5V.

** Input signal set as 4-20mA, but input 2-10V signal. When Input signal is 2-7V, the actuator can run normally; when it’s larger than 7.2V, LD5 shines.

LD6 shines

Motor temp trip

a.Too high starting frequency

b.Motor temp trip (MOT) point is not connected.

LD7 shines

a.Output signal short a.Check if output signals #11(-) & #12(+) are correct or short

b.Wrong 2-10V input signal connection to positive/negative poles

b.Check if input signals are correct(terminal #6 connected to ”-” & terminal #7 connected to ”+”)

LD8 shines

Motor over current

a.Too high starting frequency

b.Too large torque

c.Locked rotor(Ex. Clogged with debris)

LD9 shines

Manual mode – set fully open/fully close position

After setting, press ”SET” button to be deleted.

Note: When operating proportional valve driver, if LD lights (LD4~LD9) shine abnormally, please refer to the following proportional valve driver board trouble shooting table.

27


3.2.8 Problems and Troubleshooting

ON-OFF Control 1. Motor cannot run and motor overheat

Possible Cause Solution

a. Terminals #3 & #4 are powered at the same time (in parallel)

a. Check wirings

b. Capacitor out of order(if its casing bulges out)

b. Replace it.

c. Valve body rubber has aged or its torque is too large(when it takes too long to shut off the valve)

c. Rotate the hand wheel for verification or replace with a new valve body

d. Debris clogged inside the pipe d. Remove the valve body to check any clog

e. Motor shaft or bears rusted or locked e. Replace it.

2. The actuator works normally but its motor temperature is high


a. Too frequent restart a. Change system bandwidth or use 75% duty cycle

b. Too large loading(valve body torque) b. After use in a long term, it will happen regularly so its replacement is suggested

c. Too high or too low power voltage c. Check if the current is too high

d. At fully-open or fully close position, if the socket set screw interferes with the gear

d. Readjust the socket set screw and the cam(TC1&TC2)

e. Wrong power supply e. Check the power voltage.

3. The two actuators work at the same time, sometimes they work abnormally and

its motor temperature is high


a. Use in parallel a. Check their current value and add relays respectively

4. No matter it is powered or actuated by the hand wheel, the actuator cannot be

switched to fully-open or fully close position


a. The installation of actuator is not fit tightly

a. Contact Hanbell representatives

b. The valve’s torque is higher than the actuator’s torque

b. Replace with a new valve or an actuator with higher torque

c. The fixing screw of the controlling cam loosens(angle jump)

c. Refer to adjustment procedures of socket set screw and fine-tuning switch

d. The angle of the valve and the actuator after installation is not correct

d. Separate them to check the angle

28


5. The capacitor fails


a. The loading is too high(the valve’s torque is higher than the actuator’s torque)

a. Replace with a new valve or an actuator with higher torque

b. Too frequent restart or too high ambient temperature

a. Replace it and change to 75% duty cycle

c. Lifetime limit c. Check its capacity value and appearance every year

3.2.9 Proportional Control

1. When the light indication of the proportional valve driver board is normal, but the actuator cannot work normally or only can switch between fully-open and fully-close positions.


a. Wrong input signal connection to positive/negative poles (input signal failure)

a. Check if input signals are correct(terminal #6 connected to ”-” & terminal #7 connected to ”+”)

2. Proportional control failure


a. Variable resistance (VR) failure a. Replace it

b. Variable resistance (VR) sector gear looses

b. Remove signal connections, switch the actuator to fully-close position and then reset variable resistance (VR)

c. Input signal failure c. Check if input signals are correct

d. Proportional valve driver board d. Contact Hanbell representatives

3. After operation, light indication (LD5~LD9) still shines, refer to 3.2.5.

3.2.10 Acuator Capacity Control

1. When the compressor chasing target temperature, opening of the vane actuator in percentage (%) bears a linear relation to the control signal voltage. Normally IGV opening from 100% down to 40% only brings 21% capacity change, and the adjustment form 40% to 10% can bring 34% capacity change. In this case, below table is our suggestion for adjusting IGV.

Target ice water temp.: 7℃

Range ＜6℃ 6~6.7℃ 6.7~7.3℃ 7.3~8℃ ＞8℃

When IGV≧40% IGV-10% IGV-5% stable IGV+5% IGV+10%

When IGV＜40% IGV-5% IGV-3% stable IGV+3% IGV+5%

29


2. Opening of actuator should follow the safety margin function for the adjustment. Chasing of ice water temperature by signal input. Signal output is only used for determine the IGV opening (monitor by safety margin function at all time). Because there is deviation and interference while transferring signal. There is no need to make input and output at same value. 10% deviation is acceptable.

3.3 Surge and stall

[Definition]

Surge: a complete breakdown in compression resulting in a reversal of flow and the violent expulsion of previously compressed air out through the suction port, due to the compressor's inability to continue working against the already-compressed air behind it. Surge Line: a curve formed by connecting surge points of each IGV opening. Stall: rotating stall is a local disruption of airflow within the compressor which continues to provide compressed air but with reduced effectiveness. Stall zone: stall zone is defined to confine application of the compressor under unsteady flow with small volume flow. Safety Margin Line: a curve formed by shifting Surge Line with some safety margin as the allowable maximum pressure ratio for each IGV opening.

When the centrifugal compressor is at part load, the angle of guide vane becomes smaller and refrigerant volume flow entering compressor also reduces; when the volume flow decreases to a certain extent, surge and stall may occur. As shown in Figure 3.6 Typical fixed-frequency compressor performance map, when compressors operate above the Surge Line, stall or surge may occur. When the compressor surges, discharge pressure drops suddenly lower than the pressure in condenser so high-pressured gas flows reversely to the compressor; therefore, air flows inside the compressor turbulently and it causes higher vibration and noise. Meanwhile, heat cannot be dissipated and refrigerant gas cannot be cooled down; high temperature inside the compressor may cause severe damage to high-speed shaft. In addition, alternatively varied pressure due to reverse flow may influence compressor’s moving parts so bearings may bear heavier load and be damaged. Therefore, compressor’s operating map must be confined below the Surge Line. Please refer to Hanbell selection software for more details of allowable compressor operating map to prevent surge.

30


0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

500 700 900 1100 1300 1500 1700 1900 2100

Pr

Qo[KW]

Compressor Performance Map

Below dead point is

controlled with MCC

Surge line

IGV + HGBP

Stall zone

IGV0%IGV10%

IGV20%

IGV40%

IGV100%

IGV30%

Safety margin line Compressor Operating Zone

Figure 3.6 Typical fixed-frequency compressor performance map

Surge can be detected by monitoring variation of the electrical current. When surge

occurs, continuous reverse flow will result in unstable load in the compressor. When the current differential is over 10% above average current within 5 seconds, and this phenomenon happens more than 3 times, surge may be the cause of it. Then IGV opening should be increased or hot gas bypass should be used to escape from surge range.

Note: RT series compressors are equipped with ball and rigid radial bearings so they can bear temporary surge (within 15 seconds), but cannot resist long-term surge.

Warning: After the surge happened, it may expand the interval of labyrinth seal and increase the leakage. The enlarged imbalance will increase the vibration while operating. Therefore, any surge should be avoided.

3.3.1 Equation of safety margin line

Equation of safety margin line is a polynomial of IGV actuator’s opening in percentage.

While operating, beware the pressure difference exceed the safety margin.

432Pr_

line)margin(Pr_

exdxcxbxa

safetyatratiopressure

ml

ml

a, b, c, d, e are constant, and x is opening of IGV

Safety margin on each model is not the same, please contact HANBELL R&D dept. or Sales representative.

31


3.4 Hot gas bypass

Centrifugal compressors are of non-positive displacement types. They raise pressure and temperature of refrigerant by converting kinetic energy into an increase in static pressure. Hot gas bypass is to bypass gas refrigerant or liquid refrigerant from condenser into evaporator through a proportional valve.

Function 1: When the load reaches certain value the surge would happen. To continue

the low load operation, the hot gas by pass valve can be opened to increase suction pressure and lower compression ratio.

Function 2: Apply during start up to lower starting current.

Because hot gas bypass method is to transfer compressed gas from the condenser (high-pressure side) to the evaporator (low-pressure side), it should be noticed that this volume flow might make enormous noise. It is recommended to enlarge the inner diameter of piping after the HGBP valve to keep flow speed under 10 m/sec.

In piping, the proportional valve should be installed as close as possible to the evaporator, and also at another side of suction entry (motor side), to lower the noises at suction side. Setting the piping on suction pipe can also prevent liquid strike.

Besides, a muffler should be installed at the evaporator. Hot gas bypasses to the evaporator should be prevented from liquid refrigerant inside the evaporator. If liquid refrigerant splashes and sucks into the compressor, it will result in liquid compression, which damages the compressor.

Note1: The system with hot gas bypass is inefficient. It should be avoided whenever

possible. Many system applications still require hot gas bypass in order to avoid surge or maintain constant chilled water temperatures from zero load to full load.

Note2: Required flow for HGBP depends on the difference between required minimum cooling capacity and the minimum load compressor can reach. If the IGV is at minimum opening and cooling capacity is 50%, and end user needs 20%. The pipe diameter and flow need to be considered based on the 30% difference.

Figure 3.7. Refrigerant Circuit & Motor Cooling system

32


3.5 Proportional valve

Between the ECO port of the compressor and the economizer, it is recommended to install a proportional valve near the compressor. When IGV opening is less than 10%, this proportional valve should be fully close. It is because under this loading, liquid refrigerant entering the economizer might be poured into the ECO port of the compressor instead of the suction port; when IGV opening is greater than 10%, this proportional valve could be fully open. In this case, this proportional valve should be closed in startup procedure. Principle of this effect: when IGV1 opening under 10%, the compressor entry will be like current limited control, speed up the flow and create a great pressure drop behind the IGV1 (according to Bernoulli's principle). The internal compression ratio is kept the same and the middle pressure of compressor will decrease (can be close to evaporating pressure). The liquid level of economizer is not easy to control in this condition and the liquid may enter the compressor through economizer port.

Figure 3.8. Enthalpy diagram of 2-stage compression

Condenser

Evaporator

Economizer

33


Chapter 4. Lubrication system

4.1 Oil circuit

Lubricant is driven by built-in oil pump in the compressor. Oil passes front / back bearings of motors since gears and bearings are around the high-speed shaft for lubrication. The oil system consists of an oil pump, a relief valve, an oil filter, an oil cooler and other control valves.

Figure 4.1 Schematic diagram of oil piping

After lubricant is pressurized by built-in oil pump, it passes the relief valve for modulation

of pressure and flows through pipe 1. The oil circuit is then divided into two passages, Pipe 2 & 3, which are after the oil cooler and the oil filter. Oil in pipe 3 lubricates bearings in the back of the motor and returns to the oil tank by pipe 3’. Oil in Pipe 2 enters gear box on the top, and lubricates bearings in front of the motor, the gears, and the front/ back bearings, which are around the high-speed shaft, and returns to the oil tank finally.

R1=P1-P2 ≥ 1.0 bar alarm R2=P1-P2 ≥ 1.5 bar shut down

Definition: R1: Resistance in pipe, R1=P1-P2. It includes pressure drop in pipe itself, oil

cooler, and oil filter. Please pay attention to the pressure sensor installing point.

R2：Internal resistance in compressor. It’s fixed value 2.0~2.2 bar indicates the

necessary pressure difference for compressor lubrication.

Note1: Unfortunately, power cut is common in many areas. When it occurs, chillers will be shut down abnormally, and most compressors stop without benefit of oil pumps. If hydrodynamic bearings are used, poor lubrication may damage them and reduce compressor life. Hanbell RT series compressors are equipped with rigid bearings. The oil pump starts or stops concurrently with the compressor. Unpredictable shutdown of RT series compressors during power cut is acceptable.

34


Note2: Different from hydrodynamic bearings, rigid bearings have the advantage of less kinetic energy loss as oil-less parts.

Note3: Pressure gauges should be installed separately at P1 (the outlet of the oil pump) and P2 (the outlet of the oil filter). An oil pressure differential switch should be installed on piping in between for prevention of oil loss due to clogs in the oil filter.

4.2 Oil pump

4.2.1 Specifications of the oil pump

Oil pumps built in RT series centrifugal compressors are of the gerotor type.

Item Spec O

il

pu

mp

Flow rate L/min. 20 24

Pressure difference range bar 2~4.5 2~4.5

mo

tor

Output W 311 373

Voltage V 3ψ,380V/50Hz 3ψ,220V/60Hz

Running current A 1.1 1.9

LRA A 7.9 13.7

Table 4.1 Specifications of the oil pump

4.2.2 Features of oil pump

The oil pump is volumetric type and the flow rate is constant even the pressure difference changed. System resistance equals to the sum of pipe resistance (R1) and compressor internal

resistance (R2). The compressor internal resistance is a constant value (2~2.2 bar), while pipe resistance equals to the sum of pressure drop of pipe itself, valve, oil cooler, and oil filter. The oil pump needs to build up the pressure to overcome system resistance (R1+R2). Considering the compressor internal resistance and pipe resistance in which oil filter contribute the most and shut down value 1.5 bar, the oil pump operation range is 2~4.5 bar.

35


4.2.3 Protection in oil line

Oil pump outlet pressure is set at 4 bar(@R1=2 bar) as original. Only authorized personnel is allowed to changing its setting value. Protection setting:

P2-P3 < 2.0 bar alarm P2-P3 ≤ 1.5 bar shut down

Note 1：Bearings in RT series compressors require steady oil supply for lubrication.

Note 2：Before compressor starts, oil pump must be ahead for three second.

Figure 4.2 Oil pump

Only authorized personnel are allowed to change settings of the oil

pump.

36


4.3 Oil cooler

In the oil system, an extra oil cooler is required. Please refer to Hanbell selection software for the required capacity and oil flow volume in the extra oil cooler.

Oil temperature settings for the oil cooler

Lubricant in the oil tank is pressurized by built-in oil pump and then cooled through the

oil cooler to keep its temperature between 30~55℃. Filtering by high-density mesh in the

oil filter, lubricant will absorb heat, reach optimal oil temperatures and lubricate bearings in a splashed form. Lubricant will return to the low-pressured oil tank finally. Cooling media for the oil cooler can be liquid refrigerant in the condenser or from the motor cooling outlet. A temperature sensor should be installed at the oil cooler outlet for modulation of volume

flow of liquid refrigerant to keep oil outlet temperature (Tco) between 30~45℃. Gas after

heat exchange in the oil cooler returns to the economizer and can be used again.

Tco > 45℃ or Tco < 25℃ alarm

Tco > 50℃ or Tco < 20℃ shut down

Note：Refer to Hanbell selection software for heat load of the oil cooler.

4.4 External oil filter

The external oil filter is a must in the oil circuit. It should be installed in the oil line after the oil cooler. The function of external oil filters is to filter out debris so it does not act as abrasive when oil re-circulates. The filter shell should be able to withstand oil pressure as high as 12 to 15 bars.

Hanbell external oil filter must be used. Its filtering material could be cellulose (paper)

or synthetic fiber (15~25μm). Paper can withstand flow of high-pressured oil without being torn apart. The material has to be able to block small debris without restricting oil flow too much. Cellulose (paper) as filter material is economical and works fine. Cellulose as the filter may block particles while allowing oil to pass through. There is synthetic fiber for high-end filters that has smaller passages to block smaller particles but still make fluid pass it through. There is also a kind of material that is a blend of these two materials. HANBELL provides oil filter with spec. below:

Working pressure：15bar

Working temperature：-20~100℃

Filter accuracy：15~20μm

Rated flow：100L/min

Note：The centrifugal compressor is of delicate type. It is a must to use above materials for

filtering.

If the filter is only a normal metal strainer, particles will enter the compressor and damage bearings badly.

37


4.5 Oil & refrigerant circuits

In the compressor, oil is sealed and separated from the discharge volute and the motor by labyrinth ring assembly. A labyrinth ring is a non-contact ring so some amount of gas may still leak to the low-pressured oil tank. Two oil heaters are equipped in the bottom of the oil tank for heating to separate liquid refrigerant from oil. Thereafter, gas reaches the internal oil separator for the second oil separation. Purified gas then returns to the suction casing through the refrigerant return pipe.

The other possible oil leak is in lubricant circuits. When the compressor starts, oil for lubrication of front & back bearings around the motor shaft might leak to the motor casing because medium pressure in the motor has not been built up completely. Leaked oil will accumulate in the evaporator. In general, an ejector is applied to recirculation of leaked oil. Power of ejection comes from high pressure in the condenser or middle pressure in the economizer. Gas with oil will be separated firstly by internal oil separator in the oil tank, and gas will re-circulate stably without fluctuation of oil level. For better evaporation of liquid refrigerant in the oil tank, oil heaters in the bottom of the oil tank are used for heating.

Figure 4.3 Schematic diagram of oil & refrigerant circuits

Some amount of oil might mix with suction gas and would flow to the compressor from

the evaporator. After the inlet nozzle, there is a mechanism which can bring oil to the bottom of suction casing for oil separation. An ejector should be applied to oil recirculation from the suction casing to the oil tank as shown in Figure 4.3. Power of ejection comes from high pressure in the condenser or middle pressure in the economizer.

Note：RT series compressors are equipped with ball and radial bearings. Therefore, the

amount of lubricant need is much lesser. This design minimizes possibility of oil leakage to the system.

38


4.5.1 Oil temperature control in the oil tank

The oil temperature should be kept above ET+20℃ by use of the oil heater to avoid

refrigerant migration into the oil tank. If oil mixes with liquid refrigerant inside the oil tank, lubrication effect would drop seriously. Therefore, compressor bearings will be damaged easily. It is necessary to heat oil so liquid refrigerant can evaporate and re-circulate in the system.

Control of oil temperatures in the oil tank is by means of a temperature sensor in the oil

tank. When the oil temperature is under ET+20℃, oil heaters should be turned on to

activate liquid refrigerant evaporation; when the oil temperature is detected over 45℃, oil

heaters should be turned off. In normal conditions, during operation of the compressor, heat is produced by moving parts can help maintaining the oil temperature.

T3 < ET+20℃ oil heater ON (It’s forbidden to operate the compressor.)

T3 > 45℃ oil heater OFF

T3 > 60℃ alarm

T3 > 65℃ shut down

Note：

1. ET is evaporating temperature for chiller unit. Saturated temperature cab be converted from the pressure in evaporator.

2. Oil heaters should be controlled individually. During temporary stop or restart 24 hours ahead after a long stop, oil heaters should be turned on for pre-heating. Please follow the temperature setting above during operation of the compressor.

When the oil temperature is under ET+20℃, do not start the

compressor.

Oil heater specifications

Two UL approved 500W oil heaters have been equipped in the oil tank as standard

accessories. Specifications：500W/ 220V; IP 54; UL approved

Note1 : The oil temperature inside the oil tank could be kept in normal range because heat is transferred to oil from bearings and gear during running. But if large amount of oil is retuned from the evaporator or ambient temperature is low, oil temperature might be insufficient. Hence, oil heaters should be used to make sure the oil from oil pump is free of liquid refrigerant and temperature in oil tank is in safe range.

If lubricant mixes with liquid refrigerant, bearings and gears cannot be lubricated effectively. This will result in damage to the compressor.

Note2 : There are oil separators installed for effective oil separation at oil return and refrigerant return ports in RT series compressors. Please refer to item 13 & 14 in Figure 4.4. Besides, gears are installed in the gear casing to efficiently minimize fluctuation of oil level due to high-speed rotation. Furthermore, the gear casing

39


also reduces oil to mix with refrigerant flow so oil flow from the compressor to the system could be minimized.

Figure 4.4 Oil separator

Refrigerant heater specifications

Two UL approved 300W oil heaters have been installed in the compressor casing. Before restart of the compressor after shut down for a long time, please turn on refrigerant heaters at least 24 hours to make temperature inside the compressor higher than system temperature and ambient temperature. Therefore, it can prevent condensation of refrigerant inside the compression chamber.

Figure 4.5 Refrigerant heater

Specifications： 300W; 110V or 220V; IP 54; UL approved

Note: If ambient temperature is low, it is recommended to turn on refrigerant heaters

during stop of compressors.

40


Oil pressure in the oil tank

Pressure in the oil tank must be kept as low as possible for oil return to the oil tank finally. A pipe is connected between the oil tank and the suction casing (item 15 in Figure 4.4). Therefore, in normal condition the pressure difference between oil tank and suction side is -0.2~0.5 bar.

Note：1. If oil pressure is abnormal inside the oil tank, the possible cause might be that the

labyrinth ring for separating high/ low pressure is damaged and a large amount of refrigerant leak as shown in Figure 4.6.

2. When the oil tank pressure (P3) is 0.6 kg/cm² higher than the suction pressure

(Ps), system should provide an alarm signal to users. When the oil tank pressure is 0.8 kg/cm² higher than the suction pressure, system should be stopped for protection and troubleshooting.

P3-Ps ≧ 0.6kgf/cm2 alarm

P3-Ps ≧ 0.8kgf/cm2 shut down

Figure 4.6 Labyrinth r ing

RT series compressors are equipped with rigid bearings and fine oil separators.

Therefore, oil carry-over in the system is much less. For oil return from the evaporator, orifice size of the oil return outlet of the evaporator should be confined. Suggested orifice sizes are shown as the table as below. Too much liquid refrigerant will cause poor lubrication for bearings resulting in serious damage to the compressor.

Model Size of orifice

RT-120~140 RT-111

φ2

RT-160~200 RT-221, 161

φ3

RT-240~280 φ4

Unit: mm

41


4.6 Lubricants

The main functions of lubricant in the centrifugal compressor are lubrication and cooling. Bearings used in RT series compressors require a small but steady volume of oil for lubrication. Please pay more attention to oil temperature which is crucial to compressor bearing life. High oil temperature will reduce oil viscosity and result in poor lubrication and heat dissipation in the compressor as well. It is recommended to keep oil temperature

between 30~45℃ and oil viscosity over 10mm2/sec at any temperature.

4.6.1 Lubricant table

Type HBR-B12 Unit

Specific gravity 0.982 API

Viscosity

@40℃

32.3 mm2/ sec

(cSt) @100℃

5.71

Flash point 257 ℃

Pour point -51 ℃

Acid number 0.05 mg KOH/g

Water content <100 ppm

Note: Use of oil other than HBR-B12 will result in HANBELL’s non-warranty.

4.6.2 Precautions in changing of oil

1. Use HANBELL approved oil and do not mix different brands of oil together. Choices of

oil should match characteristics of refrigerant. Some types of synthetic oil are incompatible with mineral oil. Oil in the compressor should be totally cleaned up in the system before charging different brands of oil. Charge the compressor with oil for the first start to ensure that there is no mix at all.

2. When using polyester oil for chiller systems, please make sure that oil does not expose to the atmosphere for prevention of change in its quality. Therefore, it is necessary to vacuum the system completely when installing the compressor.

3. In order to secure no moisture in the system, it is suggested to clean the system by charging it with dry Nitrogen and then vacuum it repeatedly as long as possible.

Note: When vacuuming the system, please notice that into consideration “When pressure

is low, moisture will be condensed so recharge of some dry Nitrogen is necessary.

42


4. If the motor has burned out, acid debris may still remain inside the system and the oil becomes acid which will deteriorate the insulation of the motor. Therefore, it is a must to change oil and clean the system when changing the motor. Please follow the procedures mentioned above to change oil in the system. Check acidity of oil after 72 hours of operation and then change it again until acidity of oil becomes normal.

5. Please contact Hanbell local distributors/agents for choices of oil.

Figure 4.7 Oil sight glass (Oil level)

Note: Users can refer to Figure 4.4 for charging of oil. After opening the oil separator flange, oil can be charged at the port, item16; or oil could be charged by vacuuming the angle valve, item13.

When the compressor is running, please check white floating ball inside

as oil level indicator and it’s recommended to maintain oil level between High and Middle; if the level is higher than High, oil must be drained to keep the level below the bottom of gears; if the level is between Middle and Low, oil return must be done or oil charge must be replenished; else if the level is lower than Low, the compressor must be stopped emergently to prevent dry wear of oil pump and bearing failure.

High

Middle

Low

43


4.6.3 Oil change

Check oil periodically lubricant every 10,000-hour running. For the first operation of the

compressor, it is recommended to change oil and the external oil filter after 2,000 -hour running. Check the system whether clean or not and then change oil every 20,000 hour or after 3-year continuous running under good condition.

Item Maintenance(hr) Note

Change oil and external filter 2,000 hrs After the first operation

Check oil 10,000 hrs After continuous running

Change oil 20,000 hrs

or 3 years

After continuous running

Table 4.2 Maintenance for oil change

In order to avoid debris in the oil filter which may lead to bearing failure, the oil pressure

differential switch is recommended to be installed. The switch will sense when oil pressure differentials between the primary and secondary sides exceeds the critical point. Then the compressor will be shut down automatically to prevent bearings from damage due to oil loss

Note1: Pressure gauges should be installed separately at P1 (the outlet of the oil pump)

and P2 (the outlet of the oil filter). An oil pressure differential switch should be installed on piping in between for prevention of oil loss. (Please refer to the Figure 4.1 Schematic diagram of oil piping)

Note2: It is recommended replacing the external oil filter core after test of the chiller in the

factory. Otherwise, debris might clog up the external oil filter. Note3: It is not necessary to fill additional oil when compressor working in chiller normally.

Unless there is oil carry-over or oil pump maintenance. To fill the refrigeration oil, the oil pump should be connected to the service valve beneath compressor oil tank. (The amount of the oil should be ensured before restart the chiller.

Note4: Using refrigeration oil incorrectly, including using non-dedicated HANBELL oil, over

filling, inferior quality filter, improper mesh specification and improper operation might damage the compressor. Only trained technicians are allowed to finish the maintenance work. Any proper service requirement, please contact HANBELL technicians.

44


Chapter 5. Motor

5.1 Motor cooling

The motor in RT series compressor is cooled by liquid refrigerant that comes from the condenser. Solenoid valves, expansion valves, or orifices should be installed on piping before the suction flange as a throttle for inflow control. In order to keep the motor

temperature between 30~90℃, it is estimated that heat exchange is equal to around

6~10% of motor power input for motor cooling.

Figure 5.1 Motor cooling system

Figure 5.2 Two aux inlets for cooling

Note1: Two auxiliary injection inlets on the motor casing are the main source of motor coil cooling, please make sure both of them are connected.

Note2：Change of the two auxiliary liquid injection connector is prohibited.

2 aux injection inlets Main injection

inlet

Aux injection outlet Main injection outlet

45


Liquid returned from motor: In heat pump, VFD application, or low compression ratio system, the liquid refrigerant might accumulate inside the motor casing. This is because in low compression ratio condition, the pressure difference between Economizer (PECO) and motor casing (Pmotor) is not enough to cover the pressure drops in the piping line and the liquid refrigerant could accumulate in motor casing. Auxiliary injection outlet should be connected to the evaporator to prevent possible liquid flooding. It is a must to install the auxiliary injection outlet in the working conditions below and use angle valve to control the flow rate to the evaporator.

1.Low compression ratio: Working condition is CT-ET<15℃

2.VFD system：Operational frequency is lower than 60%~80%of rated frequency

3.Heat pump system

Single-stage compression system (Without Economizer):

In single-stage compression system, the outlet of motor injection port is connected with evaporator. The pressure in motor casing is similar to evaporating pressure and this will cause condensation on the surface and deteriorate the insulation of main power terminals. In addition, when the motor casing pressure is lower than bearing housing pressure, the lubricant will flow into the motor casing and then enter the evaporator. Therefore, it is a must to install MPV(Minimum Pressure Valve) in the main motor injection outlet pipes and make sure to keep the standard below:

1 kgf/cm2≦Motor Pressure(Pmotor) –Evaporating pressure(Ps)≦ 1.5kgf/cm2。

Temp. sensors Pt100 or Pt1000 – for motor coil temp. monitoring

There are 4 sets of Pt100 or Pt1000 temperature sensors mounted in the motor coil.

Adjust flow of liquid injection to motor by temperature feedback of these sensors. Choose the highest temperature among these four sensors for controlling the motor coil

temperature between 30~90℃.

Note: When temperature in any set of Pt100 or Pt1000 temp sensor reaches 90℃, the

controller should raise the alarm. When the temperature reaches 95℃, the

compressor should stop until the cause of high temperature has been eliminated.

Tmo > 90℃ alarm

Tmo > 95℃ shut down

Motor temperature after cooling should be higher than ambient temperature to prevent condensing water which might cause insulation failure of wiring terminals.

46


Protector connect method: 1 & 2 are PTC protector contact, A & B are concurrent, O1 is contact for 2 pairs of Pt100, C & D are concurrent, O2 is contact for the other 2 pairs of Pt100.

Figure 5.3 Protection terminal plate.

Specifications: Pt100 sensor Recommended max. meas. Current for heat coefficient <0.1K – DC 1 ~ 3 mA

Heating coefficient - 10mΩ/K

Sensor resistance at 0℃ - 100Ω±0.12Ω

Change of resistance 0 ~ 100℃ - 0.385Ω/K

Insulation test voltage U is – AC 1.5kV

Figure 5.4 Pt100 sensor

Specifications: Pt1000 sensor Recommended max. meas. Current for heat coefficient < 0.1K – DC 0.2 ~ 2mA

Sensor resistance at 0℃ - 1000Ω±1.20Ω

Change of resistance 0 ~ 100℃ - 3.85Ω/K

Insulation test voltage U is – AC 1.5kV

Figure 5.5 Pt1000 sensor

47


1. Please specify Pt100 or Pt1000 sensors when placing orders to Hanbell. In addition, all models can be equipped with Pt100 or Pt1000 sensors to precisely measure motor coil temperatures for control of motor cooling.

2. If the compressor is for high voltage or VFD application, the shielded wire need to be used in signal wire to avoid signal interferences.

5.2 Motor protector

In order to protect RT series compressors, three PTC thermistors are installed in the motor coil. These thermistors are connected to a motor protector, INT69HBY, to monitor motor coil temperatures and discharge temperatures as well. If any target temperatures exceed temperatures of respective PTC thermistors, PTC resistance will be higher than the limit and it results in INT69HBY trip. After cooling down below the reset standard, there will be 5-minute delay for the first trip and 60-minute delay for the second trip. When these periods have expired, the relay resumes automatically. Three consecutive trips within 24 hours lead to lockout.

Technical data of INT69HBY INT69HBY motor protector monitors phase loss, phase sequence, motor temperatures, and discharge temperatures with manual reset.

● Supply voltage AC 50/60 Hz 115/120V-15.....+10% 3VA AC 50/60 Hz 230/240V-15.....+10% 3VA

● Relay output Max. AC 240V, Max. 2.5A, C300

min. ＞ 24V AC/DC, >20 mA

● Ambient temperatures

-30 ~ +70 ℃

● Phase sensor

3 AC, 50/60Hz, 200 ~ 575 V±10%

A S e t : M o t o r P T C T e r m i n a l

M o t o r p r o t e c t o r c o n n e c t i o n d i a g r a m

i n d i c a t e s P T C s e n s o r e x c e e d s

i t s r e s p o n s e t e m p e r a t u r e

P o w e r

P o w e r

Motor

Supply

Button

Press

(NC)

Temp. PTC

Temp. PTC

Discharge

Oil

Relay

Output

Error Blink Codes

PTC Temperature Error

1st: 5min time delay after PTC < R reset

3rd: Lockout after three consecutive PTC

2nd: 60min time delay after PTC < R reset

Timer delay active (PTC < R reset)

Short

interruption

Phase failure

Internal error

temp errors within 24hrs

Phase sequence

Long

interruption

Auto reset for INT69HBY

,but not for M-PI-S28

Figure 5.6 Blink code of INT69HBY

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Figure 5.7 INT69HBY & PTC thermistors connection diagram

Phase loss and phase sequence 1. The phase monitoring of phase loss & phase sequence works after the motor starts 1

second (power on L1-L2-L3), and lasts 10 seconds (t0 + 1sec to t0 + 11sec) 2. If one of these parameters is incorrect, the relay locks out (M1-M2 is open). 3. The lockout can be cancelled by main reset of approx. 5 seconds (disconnect L-N)

Note: In order to make sure phase loss and phase sequence protection function well,

please connect L1, L2, and L3 to the motor side as Figure 5.6 shown.

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Motor temperature The motor temperature is constantly measured by thermostat (PTC) loop connected on S1-S2. If detected temperature exceeds setting its resistance will increase above the trip point then the output relay trips (M1-M2 is open). After cooling down below the response temperature, 5-minute delay is activated. After delay has elapsed, the relay pulls in again (M1-M2 is closed). The time delay can be cancelled by main reset of approx. 5 seconds (disconnect L-N).

Other major functional descriptions are as below: 1. After the supply voltage has been connected, a three second initialization period follows.

Provide the PTC chain resistance is below the reset threshold (2.75kΩ), the relay trips after these 3 seconds have expired.

2. 1 to 9 PTC thermistors with different nominal response temperature may be connected serially to the PTC input.

3. If any thermistor resistance increases above trip level the relay drops out. This failure results in a lockout. (5 minutes delay for 1st PTC failure, 60 minutes delay for 2nd failure, lockout for 3rd failure.)

4. If a rapid temperature increase is detected (locked rotor condition), the output relay drops out. This failure results in a lockout.

5. The phase monitoring of the three phase motor voltage becomes active 1 second after motor has started, for duration of 10 seconds. In case of a wrong phase sequence or a phase failure, the relay switches of and locks.

6. The Lock-out and delay time may be lifted by cycling the power off for approx. 5 seconds.

7. To avoid nuisance tripping due to reverse running after shutdown (pressure equalization), the phase monitoring function is only re-enabled approx. 20 seconds after motor stop.

8. A dual LED (red / green) provides additional information about the motor protector and compressor status.

9. The relay is fed out as an N/O dry contact, which is closed under good conditions. 10. Sensor and supply circuits are galvanic isolated. 11. The motor protector is not suitable for application of frequency converters.

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5.3 Electrical data and design

5.3.1 Motor design：Y-ΔStarting

The Y-Δmotor connects the motor coil by Y connection during starting therefore

reducing voltage on coils to 1/√3 of input voltage and reconnects the motor coil by Δ

connection after starting. In doing so, starting current can be thoroughly decreased. It is called voltage-drop starting.

The Y-Δ motor connection method is shown in the following motor wiring diagram: In Y

connection, MCM, MCS are inductive while the motor leads Z, X, Y are tied together as neutral connecting as letter Y. After timer set period (till peak value decreases), MCM, MCS become deductive. Around 0.25 sec later, MCM, MCD are inductive, they turn out Δ connection.

Full load Amper

Starting

Current

Time

I (AMP)

Y- shift time 0.25~0.5sec

Figure 5.8 Y-Δ starting diagram

Attention : After Y start, MCM & MCS are deductive for 0.25sec and then MCM & MCD

are inductive for Δ run. Within transient 0.25sec, a pseudo short circuit might occur due

to inappropriate action of contactors then causing compressor trip. When it occurs, we

recommend you use adjustable Y-Δ timer to lengthen the time span for MCM, MCS

deduction - MCM, MCD re-induct from 0.25sec to 0.5sec directly in the micro controller or

the PLC program. Please refer to Y-Δshift time diagram for details. Because the motor is

not powered during Y-Δ shift. A shorter Y-Δshift span is suggested to prevent the second

start due to decreasing rotation speed. However, if the Y-Δshift span is too short, the

aforementioned pseudo short circuit might occur.

5.3.2 Characteristics of Starting

● Y-Δ 1. Starting current in Y connection is 1/3 of lock rotor ampere. 2. Starting torque in Y connection is 1/3 of lock rotor torque. 3. Acceleration of the motor rotor becomes smaller at full-load starting. Therefore

compressors require starting at partial load (=actuator 0％).

● Soft-start features 1. Starting current is 3 times higher of rated current ampere.

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2. Soft-starter could set up the starting time, longer the starting time, less the ampere it has. For more details, please refer to technical documents of each manufacturer. ● Direct start 1. Starting current of high voltage motor is 6~7 times higher of rated current ampere. ● Step-down start 1. High voltage motor could operate with high voltage step-down transformer. Any technical advice, please contact Hanbell.

5.3.3 Motor design：Direct on line start/soft start/inverter start

RT series compressors with high voltage motors can start by direct start as below shown..

Figure 5.9 Wiring for high voltage

RT series compressors with low voltage motors can start by Y-Δ start, soft start and

inverter start as below shown.

Figure 5.10 Wiring for low voltage Note: In case of soft start and inverter start, bridges must be installed for wring of the same phase to prevent current imbalance.

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5.3.4 MCC & LRA

Model Starting

Method voltage Motor

MMC

(A)

LRA

(A) Model

Starting

Method voltage Motor

MMC

(A)

LRA

(A)

RT-120

Y-△

380V A 702 2840

RT-200

Y-△

380V A 1177 6149

B 944 3815 B 1632 6981

460V A 580 2635

460V A 981 5526

B 787 3070 B 1357 6534

DOL

6kV A 47 217

DOL

6kV A 77 353

B 62 303 B 105 412

10kV A 28 130

10kV A 46 212

B 37 182 B 63 247

RT-130

RT-140

RT-111

Y-△

380V A 811 3518

RT-240

Y-△

380V A 1356 7448

B 1088 4846 B 1849 7911

460V A 670 3263

460V A 1180 4214

B 907 4517 B 1536 7338

DOL

6kV A 53 250

DOL

6kV A 90 357

B 70 310 B 117 442

10kV A 32 150

10kV A 54 214

B 42 186 B 70 265

RT-160

Y-△

380V A 944 3815

RT-260

RT-221

Y-△

380V A 1632 6981

B 1177 6149 B 2025 8522

460V A 787 3070

460V A 1357 6534

B 981 5526 B 1678 7903

DOL

6kV A 62 303

DOL

6kV A 105 412

B 77 353 B 128 470

10kV A 37 182

10kV A 63 247

B 46 212 B 77 282

RT-180

RT-161

Y-△

380V A 1088 4846

RT-280

Y-△

380V A 1632 6981

B 1356 7448 B 2163 9018

460V A 907 4517

460V A 1357 6534

B 1180 4214 B 1794 8390

DOL

6kV A 70 310

DOL

6kV A 105 412

B 90 357 B 137 520

10kV A 42 186

10kV A 63 247

B 54 214 B 82 312

Table 5.1 MCC&LRA 1. For chiller: If the maximum operation working condition for cooling is higher than

CT/ET=40/13℃, please select B motor.

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2. For Heat pump: If the maximum operation working condition for heating is higher

than CT/ET=52/14℃, please select B motor.

3. Motor of T(dual-IGV)&E(High efficiency) are same as standard.

5.3.5 Grounding

Grounding point in electric system normally is a neutral point. Exposed compressor conductor should not be electrified in normal use. But there is possibility that the compressor is electrified under malfunction condition. For security purpose, HANBELL strongly recommends to ensure the grounding during installation.

Suggestion: a. Dedicated M12 grounding screw (instructed in terminal box) should be reliably

connected with grounding wire. b. Metal sheath of power cable, palpable threading pipe, cable metal trunking, cable

trays should be grounded. c. Metal sheath of armored control cable, non-armored or non-metallic sheathed cable

should be grounded. d. Power cable grounding wire should use copper wire or tinned copper braided wire,

and the cross-sectional area should follow below table:

Power cable (mm2) Grounding wire(mm2)

120 and lower 16

150 and higher 25

Note：Resistance of grounding should not be higher than 8Ω .

5.3.6 Insulation for high voltage main terminals

5.3.6.1 Method 1: After checking the phase sequence and the rotation direction of the motor, insulation

work must be done on main terminals for voltage higher than 6000V. MATERIALS: 1. LOCKTITE Cleaning liquid 2. 3M SCOTCHFIL gray electrical insulation materials 3. 3M SCOTCHKOTE paints 4. Plastic insulation tapes HANBELL will not provide the materials above because all of them can be sourced

locally.

Steps：

1. Shut down the power of the compressor. 2. Clean the dust, water, and oil on terminals by cleaning liquid. 3. Apply 3M SCOTCHFIL gray electrical insulation materials on the joint parts to make it

smooth. 4. Apply 3M SCOTCHKOTE paints on the ceramic parts of power bolts up to 1/2”position.

Apply 3M SCOTCHKOTE on the power bolts where gray electrical insulation materials had been applied and the on cable for 10”long from power bolts. Then, apply SCOTCHFIL gray electrical insulation materials on the surface again.

5. Use plastic insulation tapes to stick the whole painting layers. 6. Use 3M SCOTCHKOTE paints again for moisture prevention

5.3.6.2 Method2:

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Use Hanbell RITA- CBTM 2050 Heat shrinkable tube and insulate the wiring terminals with for voltage higher than 6000V.

Materials：

1. High voltage insulation tapes 2. RITA- CBTM 2050 Heat shrinkable tube 3. Heating by blowlamp Steps: 1. Put heat shrinkable tube into high voltage cable and tighten R type clip based on

regulation. 2. Move pre-inserted heat shrinkable tube to proper position (The heat shrinkable tube

should cover more than 30mm of white ceramic part of the terminal, and the cable and terminal joint part is not allowed to be exposed.)

3. Use blowlamp to heat up heat shrinkable tube to make the surface becomes

tight.(heating temperature is above 110°C)。

4. Use high voltage insulation tapes to wrap both side of heat shrinkable tube to prevent

it from moisture (As figure 35 below)。

Figure 5.11 Heat-Shrink Tube Diagrammatic Sketch for Covering

5.3.7 Protective measures of electric shock

To prevent electric shock accident, compressor operating under electrified condition or electrified while shutting down, please follow the protective measure:

1. Around electrified part should place mark of awareness like “HIGH-VOLTAGE, DANGER”.

2. Using railing and partition to prevent unconscious personnel get close to electrified area. Barriers do not required to be locked, but need to be set and cannot be moved unconsciously.

3. Establishing protective fence surrounding the compressors and the units with 1.5m safe distance to prevent direct contact of electrified device.

Suggestion: 1. Regular setting of leakage protection should higher than 50mA, in humid region,

25mA will be more proper. 2. Terminal connecting voltage should not larger than 50V, in humid region: 25V. 3. Grounding resistance should not larger than 500Ohm. 4. Air cut board (ACB) normally placed with leakage breaker, please refer to relative

operating setting.

Insulation Tape Sealing Place

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5. Once leakage breaker launched, please check if the insulation of every device and wiring setting are correct, Please launch the system after check. Please contact device supplier of there is any problems.

Note:

1. Between motor casing and ground, resistance = 0Ω , potential difference = 0V.

2. Between device casing and ground, resistance = 0Ω , potential difference = 0V.

3. Between drive and device casing, resistance = 0Ω , potential difference = 0V.

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5.4 Compressor Electrical and Safety Practices

5.4.1 Electrical Safety Precautions:

1. Once connected to the compressor, the power supply of the voltage would get very dangerous. Only qualified electricians and electrical engineers are allowed to the work installation. It shall be in strict accordance with the manual operation of the program as well as national regulations and safety codes before installation.

2. Users and installers shall be in accordance with the National Electrical Code as standard to provide grounding and install a protective circuit.

3. Before performing any maintenance operation, make sure the power switch is turned off to avoid accidents.

4. Before normal operation of the compressor or unacknowledged power is off, do not open the compressor terminal box to avoid danger.

5. After confirming the direction of rotation of the motor while the terminal without insulation protection, make sure to stay away from the compressor and assembling unit, to avoid the risk of electric shock.

6. When doing compressor maintenance work, inspection or parts replacement, it is a must to cut off the main power supply to the terminal discharge in order to avoid the risk of electric shock.

5.4.2 The Inspection and Preparation before Electrical Wiring

5.4.2.1 Inspection of Unpacking

1. All compressors have been passed the strict test by Hanbell. Users are unauthorized to disassemble to inspection, if necessary, please contact Hanbell Company.

2. Check the motor terminal box of compressor firstly when unpacking if there is damage, collision or deformation.

3. After first or a long time running, when compress start-up, it must uses DC2500 V meg - ohmmeter to measure motor terminal box of the main terminal and the chamber cold insulation resistance test, the insulation value shall not less than the value determined by the formula as followed.

In the formula: R ― Motor Winding Insulation of Resistance (MΩ )

UN ― Rated Insulation Voltage (V)

PN ― Motor Power Rating (KW)

When the motor is damp or the insulation resistance is lower than the calculated values, it

shall take action of drying motor stator, drying temperature must not exceed 120 ℃.

NOTE: Hanbell compressor has been test passed by national standards withstanding voltage testing. Users and installation contactor are not allowed to do the testing. If necessary, please contact with Hanbell Company.

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5.4.2.2 Cable Selection:

1. Selection of high-voltage cables shall comply with IEC183 and DL401 "high voltage cable guide for the selection" standard.

2. Low voltage cable should meet the IECA S-19-81 standard, 600V insulated wire, insulation - Haipa Dragon (Hypalon).

3. All on-site supply of cables and wires, equipment and field wiring, cable wire terminals and equipment are necessary to comply with various regulations and engineering requirements for use.

4. Location-site installation wiring and cable wires on-site installation of each device must be without prejudice to the vicinity of the device readings, adjust or repair any part of the operation.

5. Any damage to the installation were to incorrect wiring between the starter and the compressor caused responsible.

5.4.3 Power Wiring Detail:

5.4.3.1 Caution for wiring

a. Verify the nameplate ratings are compatible with the power supply characteristics and the electrical data on the nameplate. Use copper conductors to connect to power supply.

b. High voltage cable must fulfill national regular and standard. c. User and contractor are not allowed to change the shape and dimension of cable

box. d. The material of armature terminal is brass, therefore armature terminal cannot

stand the weight of high voltage cable. Installer must apply external cable shelve or tension-ease device to stand the high voltage cable. HANBELL will not provide wiring terminals.

e. Please choose wiring size of power supply under 1.25 safety margin of maximum load. Wire diameter, cross-sectional area, and current can refer to table 5.2. And elastic wire is required to make the maintenance easier and decrease transmission of vibration.

f. When tightening the cable connector of armature terminal (tighten bolt A&B), use torque wrench with the torque lower than 700kgf-cm (5/8” & 9/16” copper nut). Please refer to the figure 5.12.

g. Cable wiring and construction inspection rules must follow GB50168-92.

600V Hypalon cable (*1C)

Area of section (mm2)

Maximum permissible current (A)

Area of section (mm2)

Maximum permissible current (A)

50 200 150 410

60 230 200 500

80 280 250 570

100 330 325 670

125 370 400 760

Table 5.2

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Figure 5.12 Connection of power bolts and terminals

5.4.3.2 Making of cable end and the connector The making of cable end and the connector must be conducted by experienced personnel and follow working rules. When making cable end and connector with the voltage higher than 6Kv outside, the Relative Humidity(RH%) must be around 70%. When Relative Humidity is high, heathen ambient temperature or cable. When making plastic insulation cable end and connector, avoid the dust falling into the insulation and do not process during the fog or raining days. Please follow the requirements below:

1. Type and specification must follow the cable type e.g. voltage, core numbers, protection layers, and environment.

2. The structure must be easy, compact for installation. 3. Materials and parts must meet the technical requirement. 4. Performance must follow current national standard.

The insulation materials should be not only aligned with demands, but also compatible with cable insulation. Hardness, expansion coefficient, tensile strength, and breaking extension of these two materials must be similar. Rubber insulation cable must apply high viscosity and elasticity materials as additional insulation. When connecting core and amour clamp, must apply standard connecting tube and wiring, the inner diameter must be compatible with core and the intersecting surface must be 1.2~1.5 bigger than the intersecting surface of core. When press bond, coaxial cable press plier and mold must meet the specification requirement.

Working Inspection：

Before making the end of cable and connector, must be familiar with working information for installation, ensure the inspection procedure, and meet the demands below: 1. Ensure the insulation of cable is in good condition without damping, and no moisture is

allowed inside the plastic cable. Test the electronic performance which must be aligned with the standard.

2. The specification of accessories must be the same with cable, no injury parts, no damping of insulation materials, and sealing materials must work. Assemble

59


accessories of casing structure firstly, and the cleaning of inner tube, testing for the sealing, and dimension of structure must aligned with the requirement.

3. Working machine must be well prepared, easy to be operated, in clean condition, spare part are well prepared, and the solvent to clean the plastic insulation on the surface must follow working rules.

4. Testing the assembling if necessary

Requirement for cable processing: When making wiring terminal and connector with starting from cutting the cable until finishing, shortening the insulation exposure lead-time is the must. When cutting the cable, do not injure core of conductor and preserved insulation layer. When the fueling cable is inserted with cable, make the connector firstly, and if there are position difference, make the lower byte connector firstly. The end of cable and connector must be insulated properly, sealed for damp-proof, and mechanical protection. For the cable with the power higher than 6kV, the positive procedure to improve screened part of cable for central integration is the must and ensure the distance between terminals insulation and grounding insulation.

Wire terminal lugs a. Use and size proper crimp type wire terminal lugs in the jobsite. b. Carefully choose the size of wire lugs to match with the conductor. c. Use copper washers on power bolt connections. d. Tighten each bolt by 300kgf-cm torque force e. These connections should be under supervision of a qualified electrical engineer in

compliance with NEC or local guidelines

AWG mm2 N AWG mm

2 N

30 0.05 6.7 3 26.670 712

28 0.08 8.9 2 33.620 801

26 0.13 13.4 1 42.410 890

24 0.2 22.3 1/0 53.49 1112.5

22 0.324 35.6 2/0 67.43 1235

20 0.519 57.9 3/0 85.01 1557.5

18 0.823 89 4/0 107.2 2002.5

16 1.310 133.5 250 127 2225

14 2.080 222.5 300 156 2447.5

12 3.310 311.5 350 177 2670

10 5.261 356 400 203 2892.5

8 8.367 400.5 500 253 3560

6 13.300 445 600 304 4005

4 21.150 623 700~2000 355~1016 4450 Table 5.2 Pull-out force of crimped connections

Note:

1. Refer to UL-486A for pull-out force standard of crimped connections. 2. Ensure power supply wiring and output motor wiring are connected to the proper

terminals. Failure to do so will cause catastrophic failure of the motor.

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5.4.4 Limitation of power supply

a. Voltage limitation b. Frequency: 1. Long term running: Low voltage±5%; High voltage±2% 1. Rated frequency ±2% 2. Instant running: Low voltage±10%; High voltage±4% 3. Unbalanced: Low voltage±3%; High voltage±2%

Power of some areas is unstable. Install an additional voltage protector with mentioned voltage limitation above to ensure safe operation of the compressor.

1. Unbalanced voltages : Unbalanced voltages occur because of variations in load. When load on one or more of

the phases is different from the other(s), unbalanced voltages will appear. This can be due to different impedances, type, and value of load on each phase. Unbalanced voltages can cause serious problems, particularly for the motor. National Electrical Manufacture Association (NEMA) defines voltage unbalance as below:

voltageaverage

voltageaverage fromdeviation voltagemaximum100 voltageunbalanced of Percentage

NEMA states that poly-phase motors shall operate successfully under running

conditions at rated load when unbalanced voltage at the motor terminals does not exceed 1%. Furthermore, operation of a motor under above 5% unbalanced condition is not recommended. It probably results in motor damage.

Unbalanced voltages at motor terminals cause unbalanced phase current. This causes excessive heat to shorten motor life. If unbalanced voltage is too high, the reduced torque capability might not be adequate for the application and the motor will not attain rated speed and. Some more common causes of unbalanced voltages are: ●Unbalanced utility supply ●Unequal transformer tap settings ●Transformer failure ●Open delta connected transformer banks ●Large single phase distribution transformer in the system ●Heavy reactive single phase loads such as welding machine ●Open phase on the primary of a 3-phase transformer in the distribution system ●Blowout fuse on the 3-phase bank of power factor improvement capacitors ●Unequal impedance in conductors of power supply wiring ●Unbalanced distribution of single phase load, such as lighting A 3-phase unbalanced voltage protector is an optional accessory. Please contact Hanbell for more details.

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Chapter 6 Compressor lifting and installation

6.1 Compressor lifting

After the compressor arrives at the warehouse, check the crate if it is in good condition and check all compressor accessories with shipping documents to see if there is any discrepancy.

Each HANBELL centrifugal compressor has been fully tested at the factory and all

precautionary measures have been taken to make sure the compressor is in perfect condition during working. When lifting the compressor, it is recommended to use a steel chain, a steel cables as shown in the Figure 6.1 as below, or a safety rope, which have loading capacity of 5,000kgf.

Figure 6.1 Lifting the compressor with a steel chain or a steel cable

Make sure that the steel chain, steel cable, safety rope or other lifting equipment is

properly positioned to avoid damage to the compressor and its accessories. Keep the compressor in a horizontal position when lifting to avoid crashing on the ground, hitting on the wall or any situation that may damage it and its accessories.

6.2 Compressor mounting

The position of the compressor in the refrigeration system should be accessible and make sure that the chiller base or site is far enough from any heat source to prevent heat radiation. The compressor should also be installed as closer as possible to the power supply for easier connection. It is a must to keep good ventilation and low humidity condition in the site. Make sure that the supporter is strong enough to prevent vibration and noise while the compressor is operating.

The compressor must be installed horizontally. In order to prevent vibration when

operating, cushions or mounting pads should be installed. The installation of mounting pads is shown in the Figure 6.2 below. The tightening of bolt should still keep certain deformation tolerance on rubber pad.

※It is strongly recommended the position of the compressor is higher than the evaporator,

and the compressor mounting pad is higher than the economizer refrigerant level (Figure 6.3).

※ Please make sure to lock the mounting of the front side and back side, and it is no need

to lock the mount in the middle shown in figure 6.2 below.

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Figure 6.2 Installation of mounting pads

Economizer

Figure 6.3 Installation of Economizer

Note1: It is suggested position of compressor should be higher than evaporator, and the compressor foot base should be higher than economizer liquid level (as figure 6.3) to prevent pressure loss of liquid return, Note2: Compressor fixed bolts are required for 2 side of compressor. The middle one is not necessary.

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6.3 Compressor protection device

Protection devices as below table are basic configuration (depends on the order). Must build up protection setting as this security requirement. You shall taker their own risk if changes the setting without our permission.

Compressor device Setting point Note.

Compressor motor protector ( PTC sensor)

Trip temp.:110℃, Return temp.:100℃ Standard

Reverse phase protection (protector INT69HBY)

Standard

phase failure protection (protector INT69HBY)

Standard

Oil filter pressure difference switch

Trip pressure: 1.5kg/cm2 Optional

Motor temp. sensor Pt10/Pt1000 (motor liquid injection usage)

Temp. control 30~90℃ Standard

˙Manual reverse setting (recommended):

As compressor protection device. Compressor motor coil protection and compressor discharge temperature must connect with INT69HBY connector. In case it can react immediately when the temperature tripped. And set up the guiding light on control box. Turning on the compressor at shorted circuit to bypass protection module is not allowed, and Hanbell is not responsible for the damage.

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6.4 Compressor accessories

Hanbell designs complete standard and optional accessories according to various application requirements for safe and steady operation as well as the best performance.

● ：Standard, ∆ ：Optional

Accessory RT

Suction/Discharge flange ●

Economizer flange ●

INT69HBYmotor protector ●

IP54 terminal box ●

Refrigerant heater(300W*2) ●

Oil heater(500W*2) ●

Oil drain valve ●

Motor PTC ●

Motor temperature sensor(Pt100 or Pt1000) ●

Oil tank temperature sensor(Pt100 or Pt1000) ●

Discharge temperature sensor(Pt100 or Pt1000) ●

Lubricant ●

External oil filter △

Oil cooler(5RT) △

Oil pressure differential switch △

Mounting pad △

Actuator heater △

Ejector △

Discharge valve △

Table 6.1 Spare parts (Standard/Optional)

Note: The accessory chart is for purpose only. Actual specification and accessories enclosed might vary with different quotation and agreement respectively. If any optional accessory is required and out of above mentioned standard accessories, please contact Hanbell for detailed specification and quotation.

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6.5 Operation and maintenance

6.5.1 Compressor starting

The table below shows the required procedures and points before commissioning the compressor.

Item Procedure Note

Leakage test

1. Fill N2 to pressure13.5 kgf/cm2g. 2. No leakage within 12 hours. 3. Mark on gauge during leakage test.

Close the service valve on the evaporator.

Vacuum

1. Vacuum target value is under 757mmHg. 2. Maintain vacuum circumstance 12hours to

see if the pressure can be kept within 757mmHg.

1. The high pressure gauge should be off.

2. Open the service valve on the evaporator. 3. No electrical test

under vacuum circumstance.

Charge lubricant

1. Use pressure differential to charge lubricant (by vacuuming the angle valve on the casing of the first oil separator).

2. Add lubricant to high oil level and record the volume. 3. Disconnect built-in oil pump power. 4. Oil heaters should be operated at least

24hrs before starting of compressor and oil

temperature should be higher than ET+20℃.

Oil level should not be too high. Gear would agitate oil when oil level is too high.

Charge refrigerant

1. Check chilled water pump and cooling water pump’s operation before refrigerant charge.

2. Charge gas refrigerant till saturated

temperature is higher than 0℃.

3. Charge gas refrigerant until 2 kg/cm2g.

4. Then charge liquid refrigerant to 80％

of the standard volume.

1. If water is inside the water circuit, the water pump should be on.

2. Record the volume of charged refrigerant.

Liquid injection to the motor

1. Close the inlet stop valve completely then rotate two cycles backward.

2. Open the outlet stop valve fully.

Control settings

Confirm the following info of spec., 1. Vane actuator testing 0~100% then

100%~0%, the control signal is 4~20mA or 0~10V, the feedback signal is the same as ampere or voltage. Set open percentage at 0%.

2. HGBP valve testing 0~100% and set open at 100%.

Check rotation direction to avoid incorrect rotation.

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Start up test

1. Oil pump rotation direction test: Observe through sight glass on motor cover plate to check oil injection condition

2. Motor rotation direction test: Observe through sight glass on motor cover plate to check the direction (counter-clockwise)

3. The following conditions should be checked before the compressor start-up:

a. IGV=0% b. HGBP=100% c. Mid-pressure proportional valve=0%

4. Loading test a. After fully start is completed, the vane

actuator 0→10%, mid-pressure proportional

valve 0%→100%, HGBP kept at 100%。

b. control with normal load-unload modulation logic

c. Make sure the oil temperature after oil

cooler should be between 30~45℃. If not,

adjust the refrigerant volume. d. Make sure the motor temperature between

30~90℃.

e. The vane actuator works from 20% to 100% and the motor temperature should be

between 30~80℃.

f. At full load, observe refrigerant level in the evaporator sight glass, bubble evaporating and copper tubes should be seen slightly.

g. Discharge temperature is between 40~65℃

in general, not exceeding 75℃.

h. Vibration and sound level test. 5. Unloading test

Test the minimum capacity with HGBP and surge prevention.

1. Oil pump starts up 3 seconds prior to main motor start up.

2. Lock-out setting of high pressure at 12.5 kgf/cm²-g

3. Lock-out setting of low pressure at 1.4 kgf/cm²-g.

4. The oil differential setting is 1.5 kgf/cm².

5. The volume of liquid injection to motor can be observed by the lower sight glass of the motor casing. The liquid level should be lower than coil.

6. The liquid refrigerant level in the economizer cannot be over 1/2 of the tank to prevent liquid compression.

7. Superheat of middle pressure inlet gas is

between 0~0.5℃.

8. Measure :

Motor side : ≦

1.8mm/sec

Gear side : ≦0.8mm/sec

Sound level : < 88dB 10. When the working current is higher than MCC, unload the compressor

(IGV↓)

Shutdown test

1. Chilled water temperature increases, cooling water temperature decreases.

Vane actuator 50％→20％→10％

a. Open HGBP 0％→ 100％

b. Adjust IGV based on the Pr(max) of safety margin formula.

2. After compressor stop, oil pump must be delay for 3 seconds.

3. Make sure compressor motor stop within 30~60 seconds.

4. Check vane actuator 0％、HGBP 100

％ and oil level.

5. Check the oil level again two hours after shut down

1. The interval of start-up should not less than 20 minutes.

Some important issues as below before starting the compressor:

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1. Before the initial start at the job site, check all auxiliary facilities which should be fixed firmly. 2. In the low ambient temperature, oil viscosity should be considered. Refrigerant and oil

heaters are supposed to turn on if necessary. 3. Check all electronic equipment match the controller. 4. Check all stop valves in the system which should be opened. 5. The operating condition of the compressor after commissioning at the job-site should be

adjusted; discharge temperature will be at least 5℃ above saturated condensing

temperature and suction vapor superheat should be within 1℃ comparing to saturated

evaporating temperature. 6. Contact HANBELL or the local distributor if any abnormal vibration or noise is found at

pipeline while the compressor is running. 7. Regularly check the chiller according to national regulations and the following items

should also be checked: -Operating data -Oil level -All compressor monitoring parts -Check electrical cable connections and tightness

Note: During shipment of the compressor, all valves have been closed. After layout of all components in the system, make sure these valves are open.

6.5.2 Compressor control logic

6S 3S 3S

10% 10%

1 2 3 4 5

Oil Pump

Compressor

HGBP

Mid-pressure

propotional

valve

Procedure of start Procedure of stop

IGV1

20S

6 7 8 9 10 11 12 Figure 6.4 Control logic diagram of the start-stop

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6.6 Troubleshooting

The table below shows some problems that might occur at the jobsite. This table will only be served as a guide for engineers to understand the situation once the problem occurs.

Problem Possible cause Action

Sudden trip of the

motor thermistor /sensor

Refrigerant shortage Charge refrigerant

Unstable electricity system or power failure Check power supply

Motor overloaded Check motor condition.

Bad motor coil causing temperature rising rapidly.

Check the coil or the motor stator.

Poor insulation of the motor

Bad motor coil. Check the coil or the motor stator.

Motor power terminal or bolts are wet or frosty. Check power bolt.

Motor power terminal or bolts are bad or dusty. Check power bolt.

Acidified internal refrigeration system. Clean the system.

Motor coil running long time continuously under high temperature.

Check liquid injection condition.

Compressor starting failure or

Y-Δ shifting

failure

Voltage incorrect. Check power supply

Motor failure Replace the motor

Incorrect power supply connection. Check and reconnect it

Y-Δtimer failure. Check or replace it

Rotor jam Check and repair it

Protection device trip Check devices

Abnormal vibration and noise of the compressor

Damaged bearings. Replace bearings.

Insufficient lubricant. Check oil level of the compressor if

enough, or add some oil if necessary.

Working out of the operating limit (surge) Check the operating range.

Improper pipe system. Check the system piping.

Unbalanced motor rotor Check and balance the rotor.

High discharge temperature

Insufficient refrigerant.

Check leakage. Charge additional refrigerant and adjust suction superheat

less than 1℃

Condenser problem due to low efficiency. Check and clean the condenser.

Refrigerant is overcharge. Reduce refrigerant

Air/moisture in the refrigerant system Recover and purify refrigerant and

vacuum system.

Improper expansion valve using Replace and adjust proper suction

superheat

Oil loss Improper system piping Check the oil pump

Low suction pressure

Lack of refrigerant Check leakage. Charge additional

refrigerant.

malfunction of the expansion valve Check and reset for proper superheat

Note:

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1.The replacement of compressor internal parts should be performed by qualified service technicians only. 2.When reclaiming liquid refrigerant, chilled water pump and cooling water pump can be off; when reclaiming gas refrigerant, make sure chilled water pump and cooling water pump are running (or drain out chilled water or cooling water); when reclaiming refrigerant(liquid or gas), make sure start circuit of the compressor is open and oil heater must be powered. When reclaiming refrigerant till 1~2psi, it’s recommended to drain out refrigerant and charge nitrogen to establish positive pressure and during repair keep purging some amount of nitrogen; if the job of greater opening is done(dismantle gas return pipe of motor cover), it’s recommended to reclaim refrigerant and charge nitrogen to positive pressure, vacuum again (below 5 torr) and then charge nitrogen to positive pressure (within 8 hours, it cannot increase above 1.33torr ) to ensure remain of refrigerant in the system to the minimum.

Contents · Contents CHAPTER 1 ... CHAPTER 6 COMPRESSOR LIFTING AND INSTALLATION ... copyright of...

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